Composite molding techniques

ABSTRACT

A molded component and method of molding such a component having one or more features. At least one fibrous substrate is located in a mold. A matrix-forming material is also provided in the mold. Heat is applied to melt the matrix-forming material to form a matrix and to integrally mold the one or more features.

The present invention relates to a composite component and a method ofmolding a composite component.

BACKGROUND OF THE INVENTION

It is known to use mold composite components comprising a fibroussubstrate and a matrix. The fibrous substrate can comprise synthetic ornatural fibers and the matrix can be a plastics material. Thesetechniques are well developed for forming composite panels. Additionalfixtures, such as brackets and support members, can be bonded to thecomposite panel. This bonding process can be performed by locatingpre-formed fixtures in the mold when the composite panel is molded; orthey can be bonded in place in a subsequent process. The bonding offixtures to the composite component is undesirable since it typicallyadds an additional process step, either before or after the componenthas been molded.

The present invention, at least in certain embodiments, sets out toameliorate or overcome the limitations associated with prior art moldingtechniques.

SUMMARY OF THE INVENTION

Aspects of the present invention relate to a composite component and amethod of molding a composite component as defined in the appendedclaims.

In a further aspect, the present invention relates to a method ofmolding a component having at least one feature, the method comprising:

-   -   locating at least one fibrous substrate in a mold; and    -   providing a matrix-forming material in the mold;    -   wherein the method further comprises applying heat to melt the        matrix-forming material to form a matrix and to integrally mold        said at least one feature.

The matrix-forming material melts and the molten material can flowwithin the mold. The molten material can penetrate each fibroussubstrate to form the matrix. Moreover, the molten material can flowinto apertures, recesses or detents formed in the mold to integrallymold said at least one feature. The at least one integrally moldedfeature is formed from the same source material as the matrix. Thematrix and the at least one feature are thereby unified. It is notnecessary for the fibrous substrate to extend into said apertures in themold. Consequently, the at least one feature can be formed partially orsubstantially completely from the matrix-forming material.

The at least one feature can be defined on a surface of the component.The at least one feature can be a projection or protuberance. The atleast one feature can be a bracket, a spigot, a flange, a rib or thelike extending outwardly from a surface of the component. The methodaccording to the present invention enables integral features to beformed in a single process cycle. The resulting composite component cancomprise at least one feature molded integrally from the matrix-formingmaterial.

The at least one fibrous substrate can comprise a single continuousfiber or a plurality of fibers.

The method can comprise locating a plurality of fibrous substrates inthe mold. A second fibrous substrate can be located in the mold. Thefibrous substrates can partially or completely overlap each other. Thefibrous substrates can each comprise a plurality of fibers. The fibersin the fibrous substrates can be aligned with each other or can beangularly offset from each other. The matrix-forming material can beprovided in the mold between the fibrous substrates. The material canthereby form a flowable core. When the matrix-forming material ismelted, the molten material can flow outwardly through the fibroussubstrates. The method can comprise forming alternate layers of fibroussubstrate and matrix-forming material in the mold.

The matrix-forming material can be positioned adjacent the at least onefibrous substrate in the mold.

The at least one fibrous substrate can comprise one or more reinforcingfibers. The molten material can thereby penetrate between the fibers inthe substrate to form the matrix. The fibers can be short or longfibers. The fibers could be synthetic, for example glass or carbonfibers. Alternatively, the fibers can be natural fibers, such as cotton,wool, flax, hemp, bamboo, jute, sisal, kenaf etc. A combination ofdifferent fibers, for example natural fibers and synthetic fibers, couldbe used to provide different material properties. The at least onefibrous substrate can comprise a continuous fiber, for example formedinto a layer or wound onto a mandrel.

The matrix-forming material can be a plastics material. For example, thematrix-forming material can be a thermoset or thermoplastic material.The matrix-forming material can be a polymer, such as polyamide (nylon),polyvinylchloride (PVC), polystyrene, polyethylene, polypropylene andpolyacrylonitrile. The matrix-forming material can also be a copolymer,such as acrylonitrile butadiene styrene (ABS). The matrix-formingmaterial can be a resin or adhesive such as epoxy, melamine, orsilicone.

The fibers in at least one fibrous substrate can be substantiallyaligned with each other. For example, the fibers could be substantiallyparallel to each other. The fibers can be formed into a thread or yarn.The at least one fibrous substrate can be formed by weaving said threador yarn. The fibers could be spun into the thread or yarn. The fiberswithin the thread or yarn can be arranged substantially parallel to eachother, for example using a wrap spun yarn.

The at least one fibrous substrate can comprise threads or yarnsarranged substantially parallel to each other. The at least one fibroussubstrate could be elongate, for example in the form of a strip. Severalstrips could be interlaced to form the at least one fibrous substrate.

The at least one fibrous substrate could consist of reinforcing fibers.Alternatively, the at least one fibrous substrate can further comprisematrix-forming fibers. The matrix-forming fibers can be made from thesame material as the matrix-forming material introduced into the mold ora different (compatible) material. The matrix-forming fibers can alsomelt when heat is applied. When heated, the matrix-forming fibers andthe matrix-forming material can coalesce.

The at least one fibrous substrate can be provided as a flexible sheet,for example made of woven material. Alternatively, the at least onefibrous substrate can be provided as a pre-consolidated sheet.Typically, pressure and heat can be applied to form the pre-consolidatedfibrous sheet. A matrix can be provided for retaining the fibers in saidpre-consolidated fibrous sheet. The matrix can be formed bymatrix-forming fibers interwoven with the reinforcing fibers. Thematerial forming the matrix can be re-melted upon application of heat,thereby allowing the matrix-forming material introduced into the mold topenetrate between the fibers in the at least one fibrous substrate.

The at least one fibrous substrate and the matrix-forming material canbe introduced into the mold as separate, discrete layers. Thematrix-forming material can be provided in the mold in a pliable orplastic form. For example, the matrix-forming material could have asemisolid composition (i.e. having a viscosity and rigidity intermediatebetween that of a liquid and a solid). The matrix-forming material couldbe pre-heated before it is introduced into the mold to provide thedesired properties. Pre-heating the matrix-forming material can reduceits viscosity and rigidity and improve its flow characteristics when itis provided in the mold. Similarly, the at least one fibrous substratecould be pre-heated.

Alternatively, the matrix-forming material can be provided in the moldin a solid form. The matrix-forming material could be provided in agranular or powder form. Alternatively, the matrix-forming material canbe provided in the form of at least one sheet or ply. The ply can bepositioned in the mold adjacent to the fibrous substrate. Thematrix-forming material can comprise a filler or bulking material, suchas wood fibers. More than one ply can be provided in sections of themold requiring additional material. The matrix-forming material could beformed into a shape for supporting the at least one fibrous substratewhen it is located in the mold.

The mold can comprise first and second mold parts. The at least onefibrous substrate could be cut to size and then located in the mold.Alternatively, the at least one fibrous substrate can be cut to size inthe mold. The first and second mold parts can have shearing edges forcutting the at least one fibrous substrate.

As outlined above, the molten matrix-forming material can integrallyform at least one feature on the component. The at least one feature canbe formed contemporaneously with the formation of the matrix in a singleprocess cycle. Apertures and/or recesses can be formed in said firstmold part and/or said second mold part to form one or more features inthe component. At least one sprue can be in fluid communication withsaid one or more features. The sprue can allow molten matrix-formingmaterial to exit the mold during the method. The method can compriseproviding sufficient matrix-forming material in the mold to form thematrix and said at least one feature.

The method can comprise applying pressure to compress the materialwithin the mold. The application of pressure can promote the flow of themolten matrix-forming material within said mold. For example, theapplication of pressure can force the molten matrix-forming materialbetween the fibers and/or into recesses formed in the mold.

It will be appreciated that the method according to the presentinvention could be employed in a variety of molding techniques,including: vacuum molding or compression molding.

In a further aspect, the present invention relates to a method ofmolding a component, the method comprising:

-   -   locating at least one fibrous substrate in a mold; and    -   providing a matrix-forming material in the mold, the        matrix-forming material being provided coincident with at least        a portion of the at least one fibrous substrate;    -   wherein the method further comprises applying heat to melt the        matrix-forming material to form a matrix around the at least one        fibrous substrate. The matrix can penetrate the at least one        fibrous substrate surrounding the fiber(s) in the fibrous        substrate.

The matrix-forming material can be provided in the mold in a form whichis either solid or semisolid (i.e. having a viscosity and rigidityintermediate between that of a liquid and a solid). The matrix-formingmaterial can, for example, be heated to reduce its viscosity andrigidity. The matrix-forming material can be pre-heated to improve itsflow characteristics when it is provided in the mold.

This technique is suitable for forming components having at least oneintegral feature, such as a projection or protuberance. The features areformed from the matrix-forming material provided in the mold. Thematrix-forming material forms a matrix around the fiber(s) in said theat least one substrate and also forms said at least one integralfeature. The matrix and said at least one integral feature are moldedconcurrently. The matrix-forming material can be provided in the mold ina layer or ply. The layer or ply can be rigid or semi-rigid. The atleast one fibrous substrate can be in a rigid or semi-rigid form.

In a still further aspect, the present invention relates to a moldedcomponent comprising:

-   -   at least one fibrous substrate; and    -   a matrix;    -   wherein the component further comprises at least one integrally        molded feature formed contemporaneously with the matrix from the        same material. The at least one integrally molded feature is        formed from the same source material as the matrix. The molded        feature can be formed substantially completely from the material        which forms the matrix. The matrix and the molded feature can        have a unified, integral structure. The composite component can        be formed using the method(s) described herein.

The at least one fibrous substrate can comprise one or more fibers. Themolded feature can, for example, define a bracket, a spigot, a flange, aridge or a rib. The molded feature can extend away from the at least onefibrous substrate. The molded feature can be formed at leastsubstantially completely from said matrix material. During the moldingprocess, the matrix material flows into a recess formed in the mold toform the molded feature. The formation of the molded feature occurscontemporaneously with the formation of the matrix. The fibers providedin the at least one fibrous substrate can be provided in a layer andarranged so as not to extend into the molded feature. The component cancomprise a plurality of said integrally molded features.

The fibers can be natural fibers and/or synthetic fibers.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the present invention will now be described, by way ofexample only, with reference to the accompanying figures, in which:

FIG. 1 shows a front perspective view of a molded composite componentformed using the method according to the present invention;

FIG. 2 shows a rear perspective view of the composite component shown inFIG. 1;

FIGS. 3 and 4 are images of the molded composite component shown inFIGS. 1 and 2;

FIGS. 5A and 5B show enlarged views of a yarn for forming the fibroussubstrate used in the method according to the present invention;

FIG. 6 shows a schematic representation of the lay-up arrangement formolding the composite component;

FIG. 7 shows sample woven materials that can be used in accordance withthe present invention;

FIG. 8 shows a schematic representation of the lay-up arrangement formolding the composite component;

FIG. 9 shows a schematic representation of the lay-up arrangement formolding the composite component;

FIG. 10 shows a schematic representation of the lay-up arrangement formolding the composite component; and

FIG. 11 shows a schematic representation of the lay-up arrangement formolding the composite component.

DETAILED DESCRIPTION

Detailed descriptions of specific embodiments of a method of molding acomponent according to the present invention are disclosed herein. Itwill be understood that the disclosed embodiments are merely examples ofthe way in which certain aspects of the invention can be implemented anddo not represent an exhaustive list of all of the ways the invention maybe embodied. Indeed, it will be understood that the method of molding acomponent described herein may be embodied in various and alternativeforms. The Figures are not necessarily to scale and some features may beexaggerated or minimized to show details of particular components.Well-known components, materials or methods are not necessarilydescribed in great detail in order to avoid obscuring the presentdisclosure. Any specific structural and functional details disclosedherein are not to be interpreted as limiting, but merely as a basis forthe claims and as a representative basis for teaching one skilled in theart to variously employ the invention.

A method of molding, in particular compression molding, a compositecomponent 1 in accordance with the present invention will now bedescribed. FIGS. 1 and 2 show perspective views of the component 1; andimages showing portions of the molded component 1 are shown in FIGS. 3and 4.

As shown in FIGS. 1 and 2, the component 1 is semi-structural member formounting on an interior of a motor vehicle door. The component 1comprises a panel section 3 having a plurality of integrally moldedfeatures (denoted generally herein by the reference numeral 5). Thecomponent 1 is formed from a fibrous substrate 7 held in a solid matrix9. As shown in FIGS. 3 and 4, the features 5 are integrally molded fromthe material which forms the matrix 9 in a single, contemporaneousprocess step. Detents and recesses can be formed in the panel section 3.In the present embodiment, the features 5 include (four) mountingbrackets 11, (two) flanges 13, and (two) locating spigots 15. Thefeatures 5 could also include reinforcing ribs, ridges, bushes and thelike.

The substrate 3 in the molded component 1 comprises two layers of fabric17 each woven from a yarn 19. The yarn 19 is formed from a plurality ofnatural fibers 21 (such as flax) interspersed with thermoplastic, e.g.polypropylene polyester or polyamide, matrix-forming fibers 23, as shownin the cross-sectional view in FIG. 5A. To preserve the longitudinalstrength of the natural fibers 21, the yarn 19 is wrap spun bysupporting a central aggregate of natural fibers 21 and thermoplastic(e.g. polypropylene) fibers 23 inside a helically-wound outer fiber 25,as shown in FIG. 5B. The yarn 19 is woven to form each layer of fabric17 in conventional manner and different weaving patterns can be employedto provide different mechanical properties in the substrate 3.

The thermoplastic fibers 23 are provided in the yarn 19 to enable thelayer of fabric 17 to be consolidated into a fibrous sheet 27 (i.e. asheet containing fibers). In particular, heating the layer of wovenfabric 17 causes the polypropylene fibers 23 to melt and bond thenatural fibers 21 together thus forming a matrix. The application ofpressure allows the layer of fabric 17 to be formed into the fibroussheet 27. The distribution and alignment of natural fibers 21 in thefibrous sheet 27 is substantially uniform. Moreover, the fibrous sheet27 is resilient and can be readily handled.

The features 5, and all or part of the matrix 9, are formed from afeature-forming material comprising polypropylene and optionally afiller material, such as wood fiber or pulp. This material can, forexample, be that which is supplied under the trade name Arbofill byTECNARO GmbH of Burgweg 5, D 74360 Ilsfeld-Auenstein, Germany. Tofacilitate handling, the feature-forming material in the presentembodiment is supplied as a continuous feature-forming sheet 29.However, the sheet may be discontinuous as described below.

The molding process according to the present invention will now bedescribed with reference to FIG. 6. The component 1 is formed in acompression mold comprising first and second cooperating mold parts 33,31 each having profiled surfaces to define the component 1. Recesses(denoted generally by the reference numeral 35) are formed in thesurfaces of the first and/or second mold parts 33, 31 to define thefeatures 5.

First and second fibrous sheets 27 a, 27 b and a feature-forming sheet29 are positioned between the first and second mold parts 33, 31. Thefeature-forming sheet 29 is provided between the first and secondfibrous sheets 27 a, 27 b to form a core. The first and second fibroussheets 27 a, 27 b and the feature-forming sheet 29 can optionally bepre-heated before they are introduced into the mold.

The first and second mold parts 33, 31 are brought together to compressthe first and second fibrous sheets 27 a, 27 b and the feature-formingsheet 29, as illustrated by the arrows A in FIG. 6. The first and secondmold parts 33, 31 have shearing edges which trim the fibrous sheets 27a, 27 b and the sheet 29 to the required size when the mold is closed.The edge(s) of the fibrous sheets 27 a, 27 b could be held between thefirst and second mold parts 33, 31 to maintain the fibrous sheets 27 a,27 b in position within the mold. The first and second fibrous sheets 27a, 27 b conform to the profile of the first and second mold parts 33,31, for example to form detents and ridges in the component 1. The moldis heated to reduce the viscosity of the matrix-forming material in thefeature-forming material sufficiently to enable it to penetrate betweenthe natural fibers 21 in the woven fabric 17 and flow into the recesses35 in the first and/or second mold parts 33, 31. In the presentembodiment the mold is heated to 180-200° C. to melt the polypropylene,but different temperature ranges may be suitable for differentmaterials. By applying pressure to the first and second mold parts 33,31, the flow of the molten polypropylene within the mold is promoted.

The molten polypropylene impregnates the woven fabric 17 and flows intothe recesses 35 formed in the surfaces of the first and second moldparts 33, 31. The polypropylene of the feature-forming material therebyforms the features 5 in a single process step. The filler materialcontained in the feature-forming sheet 29 can pass between the fibers inthe woven fabric 17 and thereby travel through the first and secondfibrous sheets 27 a, 27 b into the recesses 35. The flow of moltenpolypropylene within the mold thereby forms the features 5 integrallywith the rest of the component 1 in a single process step. It is notedthat the feature-forming material may be provided to aid formation ofthe matrix encapsulating the fibers of the fibrous substrate. Equally,some of the thermoplastic fibers in the fibrous substrate may move,during molding, into the recesses and thus, in-part, form the features.

The first and second mold parts 33, 31 are cooled and the moldedcomponent 1 is removed. As shown in FIGS. 3 and 4, the mounting brackets11 and the locating spigots 15 are formed integrally with the rest ofthe component 1. In the present embodiment, the features 5 are molded atleast substantially completely from polypropylene with a relativelysmall degree of penetration of the natural fibers 21. To provide furtherreinforcement for the features 5, additional natural fibers 21 could beprovided proximal some or all of the recesses 35 in the first and secondmold parts 33, 31.

If necessary, the component 1 can be trimmed to remove excess materialafter it has been removed from the mold. For example, the component 1can be trimmed to remove one or more sprues (not shown) provided in thefirst and/or second mold parts 33, 31 to enable excess polypropylene tobe removed during the molding process. In another example, the componentmay be trimmed to remove flashes (not shown).

The present embodiment has been described with reference topre-consolidated fibrous sheets 27 a, 27 b, but it will be appreciatedthat it is not essential that the woven fabric 17 is pre-consolidated.Rather, the woven fabric 17 could be introduced directly into the moldas a flexible material. This approach may, for example, be appropriatefor mold parts having a larger draw. Similarly, it is not essential thatthe matrix-forming material is introduced into the mold in the form of apre-consolidated fibrous sheet 27. For example, the matrix-formingmaterial could be provided in a granular or powder form.

To provide a smoother finish on the component 1, a surface film could beprovided in the first and/or second mold parts 33, 31. The surface filmcould, for example, be provided on a surface of the component 1 whichwill be exposed in use (referred to as an A-surface).

As mentioned above, the yarn 19 can be woven in different patterns toform the fabric 17. By way of example, three different samples of fabric17 a, 17 b, 17 c having different weaving patterns are shown in FIG. 7alongside a pre-consolidated fibrous sheet 27. The different weavepatterns arrange the natural fibers 21 in different orientations whichcan provide different mechanical properties in the molded component 1.

Furthermore, the angular orientation of the first and second fibroussheets 27 a, 27 b within the mold can be offset to alter the mechanicalproperties of the molded component 1. The pre-consolidated fibrous sheet27 could be formed from more than one layer of fabric 17. The layers offabric 17 could be aligned or angularly offset from each other.Different types of fibers could be used in different layers of fabric 17or different fibrous sheets 27.

Rather than use a woven fabric 17, an elongate tape consisting ofaligned natural fibers 21 and/or synthetic fibers 23 could be used. Thetape can be woven and optionally pre-consolidated in the same as thefabric 17.

It will be appreciated that various changes and modifications can bemade to the embodiment described herein without departing from the scopeof the present invention.

The invention has been described with reference to a woven fabric 17having a uniform distribution of natural fibers 21. However, anon-uniform distribution of natural fibers 21 could be employed. Thefabric 17 could be woven with a non-uniform distribution to providelocalized reinforcement. Indeed, three dimensional weaving could beemployed to provide enhanced material properties.

The matrix-forming material can be provided in a variety of forms, forexample powder, granules and sheet(s). Furthermore, a non-uniformdistribution of matrix-forming material can be provided in the mold. Forexample, additional matrix-forming material can be provided proximalrecesses 35 in the mold to form the features 5.

The present invention has been described with reference to compressionmolding techniques. Compression molding techniques may be in the form ofusing the first mold part 33 and a second mold part 31. In view of theabove description, the second mold part 31 may apply pressure (viaarrows A) to the components to be molded against the first mold part 33.The second mold part 31 may therefore be replaced by a bag whereby avacuum compression method is used to compress the bag onto thecomponents 27 a, 27 b, 29 and into the first mold part 31. It is notedthat the present invention could be employed in other molding processes,for example blow molding or vacuum forming.

Although the present invention has been described with particularreference to natural fibers, it will be appreciated that it could beimplemented using synthetic fibers, such as glass fibers, carbon fibersor aramid fibers. Indeed in another embodiment of the present invention,the fibrous substrates 27 a, 27 b are formed using carbon fiber, and inparticular recycled carbon fibers. Recycled carbon fibers may beretrieved from offcuts of other known carbon fiber molding processes andthe resulting components. The recycled fibers are combed to achievesubstantially aligned long fibers, which are combined with thermoplastic(matrix-forming) fibers (for example, polypropylene, polyester orpolyamide) into a fabric or tape as mentioned above. The long carbonfibers are substantially aligned and optionally woven into asubstantially perpendicular weave, thus giving the resulting componentexcellent strength properties in its planar configuration, i.e. acrossthe component.

In this example, the feature-forming material 29 also optionallycomprises synthetic fibers. In one embodiment the feature-formingmaterial comprises short carbon fibers that are preferably recycledcarbon fibers. The short nature of the fibers in the feature-formingmaterial permits egress of the short fibers through the long fibers ofthe fibrous substrate and into the recesses of the mold part so as toform the features. This has the advantage of providing strength to thefeature.

Components formed using synthetic materials may be suited to externalapplications, i.e. those applications which are subject to moisture andgas and should be impermeable to one or both. For example, the methodmay be used to form exhaust ducts, aerofoils, car panels, etc.

As shown in FIG. 8, in a further embodiment of the present invention,the feature forming material 29 a may be provided only over the regionof the mold part where there is a recess 35 and indeed, a feature is tobe formed. This is possible because the matrix-forming fibers in thefibrous substrates fuse during molding to form a matrix. Therefore, thisembodiment further reduces the weight of the component produced by themethod because only the feature is formed from the feature-formingmaterial. With reference to FIG. 9, it is noted that the second moldpart 31, as described above, may be provided with at least one recess35. In this example, a section of feature forming material 29 a ispositioned over the recess 35. As the mold closes, e.g. as the secondmold part 31 is moved toward the first mold part 33, the feature formingmaterial 29 a flows into the recess 35. Preferably, the volume offeature forming material 29 a provided is substantially equivalent tothe volume of the recess and indeed, the feature to be formed.

With reference to FIGS. 10 and 11, in another embodiment of the methodaccording to the present invention, the method of molding takes the formof the first mold part 33′ being a cylindrical mold whereby the moldingcomponents 27 a′, 27 b′ and 29 a′, are placed inside or outside thecylinder (see 33′ FIGS. 10 and 33′ FIG. 11, respectively). In theembodiment where the components are placed inside the cylinder (FIG.10), a second mold part 31′ in the form of a mandrel is drawn throughthe cylinder to provide a force in the A direction to promote formationof the matrix and flow of the feature-forming material 29 a′ intorecesses 35′ positioned on the inside surface of the first mold part 33′so as to form features. It should be noted that the mandrel isschematically shown to have a smaller diameter than the first mold part.The diameter may be smaller for a leading edge of the mandrel (withrespect to its drawn direction) but to exert force, the mandrel diameteris substantially equal to the internal diameter of the first mold partless the thickness of the molding components 27 a′, 27 b′. In theembodiment where the molding components are placed outside of thecylinder (FIG. 11), a second mold part 31′ in the form of a cylindricalbag or the like is placed around/over the molding components 27 a′, 29a′ and 27 b′, and the first mold part 33′. Inflation of the bag orwithdrawal of air between the bag and the molding components appliespressure in the A direction to the molding components to promoteformation of the matrix and flow of the feature-forming material 29 a′into recesses 35 positioned on the outside surface of the first moldpart 33′ so as to form features. As with the foregoing embodiments, itshould be noted that the feature forming material 29 a′ in FIGS. 10 and11 may be provided in the form of a continuous sheet around the mold.Components produced by these methods may be used, for example, inexhaust ducts or the like, where tubular structures are required andintegrally molded features provide for those tubular structures to bestrong and lightweight.

1. A molded component comprising: at least one fibrous substrate; and a matrix; wherein the component further comprises at least one integrally molded feature formed contemporaneously with the matrix from the same material.
 2. A molded component as claimed in claim 1, wherein said molded feature is formed at least substantially completely from the same material as the matrix.
 3. A vehicle comprising the molded component of claim
 1. 4. A molded component comprising: at least one fibrous substrate that includes a substrate matrix-forming material and a plurality of fibers; and a feature-forming material that includes a feature matrix-forming material; wherein the substrate matrix-forming material and the feature matrix-forming material together form a matrix having at least one feature that is integrally molded while forming the matrix by applying pressure to combine the substrate matrix-forming material and the feature matrix-forming material together in a mold.
 5. A vehicle comprising the molded component of claim
 4. 6. A molded component formed by a method comprising the steps of: locating a first fibrous substrate in a mold, the mold including two recesses and the first fibrous substrate comprising a substrate matrix-forming material and a plurality of fibers; providing a feature-forming material in the mold, the feature forming material comprising a feature matrix-forming material; locating, in the mold, a second fibrous substrate at least partially overlapping the first fibrous substrate, wherein the feature-forming material is provided between the first and second fibrous substrates to form a core; and applying pressure to combine the first and second fibrous substrates substrate and feature matrix-forming material to form a matrix and to integrally mold the at least one feature, wherein the mold comprises a first mold part comprising at least one of said recesses, whereby at least the feature matrix-forming material flows through one of the first and second fibrous substrates before flowing into the at least one recess during the application of pressure, and further wherein the feature matrix-forming material is provided as two or more discrete portions of material, each of said two or more discrete portions being positioned in the mold adjacent to a respective one of the recesses, and the feature-forming material forming the core between the first and second fibrous substrates further comprising a plurality of short fibers, wherein the short fibers are shorter than the plurality of fibers in the first fibrous substrate.
 7. A vehicle comprising the molded component of claim
 6. 